BYO Guitar JS User manual

2018-0910(-)
www.byoguitar.com

Introduction
JS Guitar Intro- 1 -
California requires the following notice:
Warning
These instructions assume that you are familiar with the safe operation and use of woodworking
machinery and woodworking tools, and understand the techniques used to assemble this project. If you do
not qualify for both of these criteria, STOP building this project for your own safety. Read and understand
the owner’s manual for the machinery you intend to use, take a woodworking class or visit your local
library for more information. Woodworking machinery and tools are inherently dangerous because they
use sharp edges that can and will cause serious personal injury including amputation and death. Do not
underestimate the ability of these tools and machinery to cause injury. Never operate any tool without all
guards in place and always wear approved safety glasses. For your own safety, please heed this warning.
Warning
Always wear safety glasses or goggles when operating equipment. Everyday glasses or reading glasses are
not safety glasses. Be certain the safety glasses you wear meet the appropriate standards of the American
National Standards Institute (ANSI). Because there are various ways to cut and join wood, you can make
substitutions for the methods stated in this manual. We try to suggest the easiest methods possible.
However, only you know your skills with each piece of machinery. Never compromise your safety by using
a cutting method with which you are not comfortable. Instead, find an alternative approach that will yield
the same result.
Warning
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:
•Lead from lead-based paints.
•Crystalline silica from bricks, cement, and other masonry products.
•Arsenic and chromium from chemically treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your
exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment,
such as those dust masks that are specially designed to filter out microscopic particles.

Introduction
JS Guitar Intro- 2 -
1Contents
1 Introduction.................................................................................................................................... - 4 -
1.1 Material Check List.................................................................................................................. - 4 -
1.2 Additional tools/materials required:....................................................................................... - 7 -
2 Mockup and Fit Check..................................................................................................................... - 1 -
2.1 Check the Neck Holes in the Body for Size (Fig. 2.1) ............................................................... - 1 -
2.1.1 Enlarge Neck mounting holes in the Body....................................................................... - 1 -
2.2 Check the Mounting Holes in the Neck ................................................................................... - 1 -
2.2.1 Drilling Mounting Holes in the Neck (Fig 2.1) .................................................................. - 1 -
2.2.2 Mount the Neck on the Body .......................................................................................... - 2 -
2.3 The Bridge............................................................................................................................... - 2 -
2.4 Fit check & Alignment of the Pickups (item 11 on material list).............................................. - 2 -
2.5 Check Tremolo Claw Alignment and Fit Check (item #5 on material list)................................ - 3 -
2.6 Fit check of the Covers (Fig 2.6.1) ........................................................................................... - 3 -
2.6.1 Tremolo cover: ................................................................................................................ - 3 -
2.6.2 Audio Cover:.................................................................................................................... - 3 -
2.6.3 Truss Rod Adjustment Access Cover ............................................................................... - 3 -
2.7 Check Strap Pins...................................................................................................................... - 3 -
2.8 Check Tuner Alignment........................................................................................................... - 4 -
2.9 Check Output Jack................................................................................................................... - 4 -
2.10 Check Nut................................................................................................................................ - 4 -
2.11 Mockup and Fit Check complete!............................................................................................ - 4 -
3 Finish............................................................................................................................................... - 1 -
3.1 Finish Application Steps..................................................................................................... - 1 -
3.1.1 Solid Color finish: ........................................................................................................ - 1 -
3.1.2 Pigmented Translucent, Gel stain or alcohol dye finish: ...................................... - 1 -
3.1.3 Penetrating Stain or water based dye finish: ......................................................... - 2 -
3.2 Explanation of Sequence Steps: ........................................................................................ - 2 -
3.2.1 Sanding the Body and Neck ....................................................................................... - 2 -
3.2.2 Appling Grain Filler..................................................................................................... - 2 -

Introduction
JS Guitar Intro- 3 -
3.2.3 Applying Sanding Sealer............................................................................................. - 3 -
3.2.4 Solid Color Primer....................................................................................................... - 3 -
3.2.5 Burst and Translucent finishes................................................................................. - 3 -
3.2.6 Clear Top coats............................................................................................................. - 3 -
3.2.7 Buff finish...................................................................................................................... - 3 -
4 Assembly......................................................................................................................................... - 1 -
4.1 Installing the tuners ................................................................................................................ - 1 -
4.2 Install the Nut ......................................................................................................................... - 1 -
4.3 Neck Installation ..................................................................................................................... - 1 -
4.4 Installing the Strap Pins........................................................................................................... - 1 -
4.5 Installing the Floyd Rose Tremolo (items 4 & 5 on material list)............................................. - 1 -
4.6 Install the Pickup..................................................................................................................... - 2 -
4.7 Prep the for the Output Jack, Volume control & wiring .......................................................... - 2 -
4.7.1 Wire color coding/prep ................................................................................................... - 2 -
4.7.2 Soldering the Components.............................................................................................. - 3 -
4.8 Install the Strings..................................................................................................................... - 4 -
4.9 Tremolo Claw Adjustment....................................................................................................... - 6 -
5 Initial Setup..................................................................................................................................... - 1 -
5.1 Adjust the Guitar Neck: Truss Rod .......................................................................................... - 1 -
5.1.1 Check the Neck................................................................................................................ - 1 -
5.1.2 Adjusting the Truss Rod................................................................................................... - 2 -
5.2 String Lubrication.................................................................................................................... - 2 -
5.3 Re-check the Bridge Alignment............................................................................................... - 2 -
5.4 Adjusting the Action (string height) ........................................................................................ - 3 -
5.5 Pickup Height (Figure 5.4) ....................................................................................................... - 3 -
5.6 Intonation (Figure 5.6) ........................................................................................................... - 4 -
5.7 …Other Hints........................................................................................................................... - 4 -

Introduction
JS Guitar Intro- 4 -
1Introduction
Thank you for purchasing a BYOGuitar.com guitar kit. This kit includes everything you need to build a
complete custom guitar. In addition to the construction of your guitar, you will need to consider the
finish –natural, solid color and possibly a design that will make your guitar unique. We suggest you do
some research to determine your finish preferences. Procuring the required finishing materials,
especially if they have to be ordered, will allow expedite your guitar project.
We carry a full line of finishing products to give you the beautiful finish you are looking for, whether a
clear natural finish or a bold, colorful finish. We also carry an instructional DVD made by Behlen that will
give you step by step instructions to help you achieve the look you want for your custom guitar.
These instructions assume you are familiar with the anatomy of a guitar. Refer to Figure 1 for many of
the terms used in the assembly of your guitar.
1.1 Material Check List
In preparation for the building of your guitar, all required material should be checked both for type and
quantity. Use the following check list to ensure all piece parts are included. If you customized your
order (ex. different tuners), ensure that these parts are accounted for. Please contact BYO Guitar if
there are any discrepancies.
Fig 1 Major Components in Your JS Guitar Kit

Introduction
JS Guitar Intro- 5 -
JS Guitar Material List
Item
Component
Quantity
Description
1
 1 JS Guitar
Body
 1 JS Guitar
Neck
 Miscellaneous
materials (see
below)
BYO JS Guitar
Kit
2
 Volume/Tone
pots
 2 Knobs
 1 Switch top
 Wire: Audio
Controls
Audio Controls
3
 11 screws 3/8”
Mounting screws
Audio and Trem
Covers
4
 1
 2 mounting
inserts/screws
JS Guitar
Bridge/Tremblock
5
 Trem Claw
 Springs, 3
 Screws, 1 ½”,
2
Tremolo parts
TIP: use small
interior packing box to
inventory and organize piece
parts

Introduction
JS Guitar Intro- 6 -
6
 Arm
Wammy bar
7
 Mounting
plate, 1
 Plastic
spacer,1
 4 screws, 13/4”
Neck mounting
materials
8
 6 Tuning Pegs
 6 Washers
 6 Nuts
 6 screws, 3/8”
Tuning Peg
materials
9
 Audio Jack
Output Jack
10
 2 Holders
 2 plastic
washers
 2 screws, 1”
Strap Holder
materials
11
 2 Pickups
 8 screws, ¾”
Pickups
12
 Tremolo claw
cover, 1
 Audio cover
 Truss rod, 1
Body (back)
Access & truss
rod Covers
13
 6 strings
Strings
14
 Output Cable
 3 Allen
wrenches
Other

Introduction
JS Guitar Intro- 7 -
15
 Nut
 2 Mounting
screws
Nut
1.2 Additional tools/materials required:
Drill & drill bits
#1 & #2 Phillips
screwdriver
Soldering iron/solder
Masking/painters tape
Finishing/painting material
Sand paper 220 & 320 grit
Guitar strap
Soap or candle
Feeler gauge
ruler
Wood glue

Introduction
JS Guitar Intro- 8 -
The remainder of the assembly instructions is divided into four sections:
Section 2 –Mockup & Fit check: in this section, all components will be checked for proper
alignment and ensure that all holes have been drilled.
Section 3 –Finishing the Body and Neck: after fit check, the components are removed from the
neck & body to allow the selected finish to be applied. This will allow you to customize your guitars’
color(s). As the finishing will likely require several coats with sanding between each coat, ensure that
the finish is completely dry.
Section 4 –Construction: the final assembly is the next step - once the finish has been applied
and completely dried. In this section, all of the components are installed, internal wiring connected and
strings attached –your guitar will ready to go!
Section 5 –Setup: in this section, adjustments are made to your guitar such as the height of the
pickups.
Again, we thank you for your purchase of a BYO Guitar and we look forward to seeing pictures of your
unique guitar! We also look forward to providing you with the guitar for your next project from our
Custom Shop where you can select the wood for the body and neck as well as customizing all of the
other components.
Let us know if your music, school, church or scouting organization would like to undertake a group
project –BYO Guitar can supply multiple kits or custom guitars.
Examples of Our Custom Shop Products

Section 2 –Mockup and Fit Check
JS Guitar Section 2 - 1 -
2Mockup and Fit Check
The following steps will ensure that the base, neck, tuners, pickup, etc. are properly aligned and that all
screw holes have been drilled.
2.1 Check the Neck Holes in the Body for Size (Fig. 2.1)
1. Insert a Neck mounting screw in the Neck pocket holes;
2. Skip to 2.2 if the screw easily passes through the Body.
2.1.1 Enlarge Neck mounting holes in the Body
1. Select a drill bit that is the same size as the mounting screw;
2. Drill a test hole in a scrap piece wood –the mounting screw should
fit through the hole with no resistance;
3. Repeat 1 & 2 until you have the proper drill bit;
4. Drill the four Neck mounting holes in the Body -
ensuring the drill is perpendicular to the Body.
2.2 Check the Mounting Holes in the Neck
1. Check the neck for pre-drilled (4) mounting
holes;
2. Skip to 2.2.2 if the holes are pre-drilled.
2.2.1 Drilling Mounting Holes in the Neck (Fig
2.1)
1. Place the neck in the pocket (…you should be
able to fit the neck in the neck pocket by hand).
a. Make sure the neck is aligned properly with the pickup pocket;
b. Carefully clamp the neck in place –frets damage easily;
c. Using the 3/32 drill bit, place the bit in the hole through the body and tap it a few times
to make a mark on the neck;
d. Remove the neck from the body.
2. Determine the neck mounting hole depth.
a. Place one of the neck mounting screws with mounting plate & plastic spacer (item #7 on
material list) through the body into the neck pocket;
b. Measure the amount of the mounting screw that extends up into the neck pocket, and
mark your drill bit;
c. Double check the depth by holding the marked drill bit to the side of the neck and be
certain the drill won’t go through the fingerboard;
3. Drill the holes in the neck with a 1/8” drill bit. Make sure you don’t drill through the
fingerboard!
TIP…a
piece of masking tape
around the drill bit works
great as a depth
indicator.
Figure 2.1 Neck Mounting Holes